Method and apparatus for making rugs



Sept. 20; 1949.

R. R. CONE METHOD AND APPARATUS FOR MAKING RUGS Filed Jan. 30, .1945

2 Sheets-Sheet l Sept. 20, 1949. R. R. CONE 2,482,655

METHOD AND APPARATUS FOR MAKING HUGS Filed Jan. 50,.1945 v 2 Sheets-Sheet 2 or filaments may beintroduced'to :the interior of Patented Sept. 20, 1949 IVI-E IHGD AND APTA Arne-Felt v MAKINGmUG-s fialphlRv-flqne AugustaLGa assignorlto IRiversideMills,..Augusta, -Ga.

"Application iianuary 30, I945", SEfi'tINoI-BYERER I v13 Claims.

This invention relates to pile fabrics-, imethods of producing such fabrics and machines forefzfecting their production.

vA prior patent issued to the-:presentnapplicant on-'March 21, '1944, 'No. 2344;537, describesan article of' manufacture comprising'a =te'xtile'fi1ament -wound and stitched to form .a 'we'b suitable :for varied usesin the textile arts. :I-he-present invention-represents an advance in thewart, in .that the filament or fil'aments 'are wound-only temporarily on avmandrel. 'The windingvinechainism :may assume'the'rform' of anattachment for i commercially known sewingnnadhines, "which 1 may then stitch the web intermediate its edges without the necessity for any backing orfshet' material to maintain the textile material fin' delsired form.

Asi ith'e earlier patent referred to, one of the the type wherein the pile is'eadhesively secured to a backing, or two backings, as the casermay be. Various other applications of' the produ'cts are contemplated, however, including t'h'eiruse' for tape, braid, tapestries, portiere's; bed'covers' a'nd trimmings, to mention a few.

In accordance with the present inven'tion, a

- winding device, which=may be constructed-conveniently as a sewing machine attachmentmcmprises a support having ahea'd"rotatably lmounted thereon and means :for rotating the'headat' a predetermined speed; the head may -b'e provided Witha .1oeripheral groove to serve asuide for one :or more filaments to be wound the' filament the head and led into the peripheral igroove through a radial opening in thehead; the dlelivery end of the head may terminate'in-a-single helical thread havinga pitch 'appro ximating or slightly greater than the diameter of the material to'be wound; adjacent the delivery erid of the head, and insome cases 'supported therein -by suitable bearings, a mandrel may be positioned constant throughout its circular 'andta'ne'red portions; from the reduced-end-bf-the mandrel, the-wound or looped filamentary material maybe fed between the throat pl'ate and presser foot of -a sewing machine, where a suitable number of (Chin- 9) =stitches may be'applied to =-maintain-the fabric r-in= its assigned .form.

Due :t'o"the "helical formationon the "delivery 'endiof the -he'ad, it will be understood thatrthe @5 convolutions will be :forced along the mandrel, zu'l-tim-atelyto' the =stitching:mechanism. 'iiBy a a eproper selection 0f gear-ing; the feed :of :the Wound filament may be so related to thespeed of the machine needle or needles, thatthe stitches l o are o'f the proper lengthiand trequency toassure rproper' sewing 'of the adjacent:loops' ofthei matezrial' a'nd satisfactorily unite them' to'ifonm 'awselfsupporti-ng tape-like "body.

The article produced' rfiay be defined as a'Ftx- 'tile ifilainent' :wound to form a-'-substantially*;fiat tube having contacting 'inner-vszalls. :Adjacent "'ifilllIlS'fOf the filament are ,prefrablyiT-in-'-contact, although the use-of ia :plurality of filaments -is rcontemplated," in which case 'the "contacting ad- 20: acentiturnsa-maymot 'beformed from the same lament. wAs already "indicated theiflat tube so .LOI"-m8dmay be pr'ovidedwith one Or'more rows stitching-extending longitudinallythereof. i fin'ol'e 'cdmplete uhderstanding of the invenisvtionwwill efollow from i a "detailed description 'of s'ome o fvits iaspects with respect to *the attache i.-fdrawings iwherein:

Fig. 1 is a fragmentaryiperspective*viewishow- --.'-ing the winding device applied *to an existing'type "of-sewing machine;

:Tiga23is:arsectionalfeleviation viewofthe'winding device showing-its relationship tocertain co- 'operati-ng iparts 01 a sew in'g machine;

iFigsl-fi'fand 4 are-e1evationa1 views of a suitable 'Fig; 5=- is Y avpersp'ective'view of a sewing inazchine throat-plate;

:iEigmBis a:rperspective view the sewing 'inachi-nezripresser'ioot; I

aiplan' view of a length of an 'ai ticle produced by the present' inve'ntibng and irligz eiis-nan end'relevationview 11f the ar't'icie of -7. "The -sewing maaliineWfl shown in'Fi'g. lfis 0f 'air existzlng corifinereial type havinga base" '22 5a .pairfif needles- 2d "a press'er foot 26, a main sh it 2228 an a ba1anee-wheel"3'0. A helical gear 3'2 318 emanated on the main -"sh'aft tor -cooperation with a helical gear 34 fixed to a jack shaft fiiion'r- 30 nailed in suitable bearings 38 and lll' rn'dunted supported by bearings 52 and 54 provided by the bracket 42 and a bracket 56, respectively, for rotation parallel to the main shaft 28. The bracket 56 is likewise secured to the machine frame and provides a second bearing 58 for the hollow shaft 60 extending from the rotary head E52. n the end of the shaft 50 and spaced from the end of shaft 60, bevel gears 64 and 66, respectively, are provided to complete the train.

The head '52 contains a radial port 58 which intersects a peripheral groove which in turn terminates in a helical end 72 formed on the head. The head is provided with a counterbore I4 in which a mandrel E6 is supported for relative rotation by a suitable bearing assembly 18. The mandrel has a substantially circular section adjacent the head, for a, length sufiicient to wind a helical coil of thread, yarn or filament, which terms are used synonomously throughout the present specification and claims. The major portion of the mandrel projecting beyond the head is provided with a taper 80 however, which terminates in a relatively thin substantially rectangular end 82, care being observed to assure substantial constancy of the perimeter or circumference throughout the circular portion and taper to assuer uniform tension in the filament wound thereon.

The reduced end of the mandrel is received between the presser foot 26 and a throat plate 85 which converge at a rate corresponding to the taper on the mandrel to receive the fiat tube of material formed by winding the filament and then flattening it. The presser foot is provided with suitable openings 86 and the throat plate with similar openings 88 for passage of the needles 24 employed to sew the adjacent loops of the wound material together.

The filament 9fl'is supplied from a reel or other suitable source, not shown, and is threaded into a rounded end 5! through a passage $2 in the hollow shaft 69, whence it is led through the radial opening 68 to the peripheral groove Hi, from which it is fed to the mandrel l6 by the helical end 12 of the head, and between the presser foot 26 and throat plate 84 where the stitches 92 are formed to produce an article of the type depicted in Figs. 7 and 8.

Where other suitable means are provided to retain the wound filament in the desired fiat form, the sewing may be omitted. In other cases it may be desired to omit one of the rows of stitching shown in Fig. '7, and in still other cases, more lines of stitching may be provided. For the manufacture of rugs, Where the strips thus formed are set-up in an apparatus similar to a type chase and two backings adhesively applied, it is advantageous to provide stitching closely adjacent to both edges of the body so that the stitching itself will be embedded in the binder and serve as a key to avoid separation.

Whereas the description of the invention has relied upon a single illustration of its application, various modifications have already suggested themselves, and will suggest themselves to those skilled in the art. It is not, therefore, intended that the invention be restricted to this illustration except as specified in the appended claims.

I claim:

1. A winding device comprising a support, a head rotatably mounted on said support, said head having a grooved periphery and a helical end, a tapered mandrel adjacent said helical end, and a passage formed in said head and communieating with said groove for introducing a filament to the interior of said head and to said groove for cooperation with said helical end and. said mandrel.

2. A Winding device comprising a support, a rotatably mounted on said support, means for rotating said head at a substantially constant rate, means for introducing a filament to said head, a relatively stationary mandrel adjacent said head, and means carried .by said head for feeding said filament from said head to said mandrel at a substantially uniform rate.

3. A winding device comprising a support, a head rotatably mounted on said support, means for rotating said head, means for introducing a filament to said head, a mandrel adjacent said head, means for feeding said filament from said head to said mandrel at a substantially uniform rate, said mandrel having a varying cross-sectional peripheral shape of substantially constant perimeter.

a. A winding device comprising a support, a head rotatably mounted on said support, means for rotating said head, means for introducing a lament to said head, a relatively stationary mandrel adjacent said head, means for feeding filament from said head about said mandrel at a substantially uniform rate, said mandrel having a cross-section varying from substantially circular to substantially flat and having a substantially uniform perimeter throughout.

5. A Winding device comprising a support, a head rotatably mounted on said support, means for rotating said head, means for introducing a filament to said head, a peripheral groove provided on said head serving as a guide for said filament, said groove terminating at the end of said head in a helical face having a pitch exceeding the diameter of said filament, and a relatively stationary mandrel extending beyond said face to receive filament convolutions delivered from said head.

6. A sewing machine attachment comprising a rotary head actuated by the machine drive mechanism, means for feeding a filament to said head, means carried by said head and rotatable therewith for feeding said filament helically from said head, a tapered mandrel adjacent said head for receiving the filament from said head, said mandrel delivering said filament to a stitching mechanism operative in timed relationship with respect to said head.

'7. Apparatus for producing flattened helical bodies from filamentary material comprising a rotary head adapted to receive filamentary matemeans provided on said head for winding said filamentary material helically and positively advancing the same, a mandrel arranged in the path of said helically wound material, said mandrel having a varying peripheral cross section of substantially constant perimeter for imparting to said helicall wound material a substantially flat form, and means arranged in the path of said helically wound material to fasten it in substantially fiat form.

8. Apparatus for producing flattened helical bodies from filamentary material comprising a rotary head adapted to receive filamentary material, helical means provided on said head for Winding said filamentary material helically and positively advancing the same, a mandrel arranged in the path of said helically wound material, said mandrel having a varying peripheral cross section for imparting to said helically wound material a substantially fiat form, and

means for fastening said body along its edges to retain it in substantially flat form.

9. A method for producing flattened helical bodies from filamentary material comprising winding filamentary material to form a helix of substantially circular cross section, gradually modifying said cross section by feeding the helix along a varying path of substantially constant perimeter until the cross section of said helix is substantially fiat and retaining the body thus formed in its substantially flat condition.

10. A method for producing flattened helical bodies from filamentary material comprising winding filamentary material to form a helix of substantially circular cross section, gradually modifying said cross section by feeding the helix along a varying path of substantially constant perimeter until the cross section of said helix is substantially flat and fastening the body thus formed to retain the substantially flat condition.

11. A method for producing flattened helical bodies from filamentary material comprising winding filamentary material to form a helix of substantially circular cross section, gradually modifying said cross section by feeding the helix along a varying path of substantially constant perimeter until the cross section of said helix is substantially flat and stitching the body thus formed to retain the substantially fiat condition.

12. A method for producing flattened helical bodies from filamentary material comprising winding filamentary material to form a helix of substantially circular cross section, gradually modifying said cross section by feeding the helix along a varying path of substantially constant perimeter until the cross section of said helix is substantially flat and fastening the convolutions of the body thus formed adjacent the edges thereof.

13. A sewing machine attachment comprising a rotary head adapted to be driven in timed relationship with the machine stitching mechanism, means for introducing a filament to said head, helical means carried by said head for positively feeding said filament from said head towards said stitching mechanism in helical form, means receiving said helically formed filament and transferring it in flattened form between a throat plate and presser foot provided by said machine for stitching the filament in its flattened tape-like condition.

RALPH R. CONE.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PA'I'EN'I'S' Number Name Date 645,236 Schlegel Mar. 13, 1900 1,855,763 Kranz et al Apr. 26, 1932 1,946,853 Hollister Feb. 13, 1934 1,955,889 Perkons Apr. 24, 1934 2,117,964 Karle May 17, 1938 

